Seals for use with foil supported and catalyst structures

Abstract

Described herein are flexible seals for directing fluid flow in a tubular reactor, such as a reformer, for enhancing heat transfer and reactor efficiency. The seals can be made of corrugated metal foil that is expandable in the radial direction for accommodating the expansion and contraction of reactor components in the tubular reactor during operation. The seals can block or redirect fluid flow through the reactor. Fluid is directed to the interior of the reactor by the seals and bypass around the outer circumference of the reactor components is reduced or eliminated.

What is claimed is: 
     
       1. A reactor comprising: a) a reactor tube having an inner wall surface; b) a reactor component, the reactor component having an outer circumferential face, a top surface and a bottom surface, the reactor component being positioned in the reactor tube such that the outer circumferential face of the reactor component faces the inner wall of the reactor tube and a gap exists between the outer circumferential face of the reactor component and the inner wall of the reactor tube; c) a flexible seal in direct contact with the inner wall surface of the reactor tube and the outer circumferential face, wherein the flexible seal is in contact with the top surface and the bottom surface of the reactor component, a portion of the flexible seal being positioned to block fluid flow through the reactor between the outer circumferential face of the reactor component and the inner wall of the reactor tube. 
     
     
       2. The reactor of  claim 1 , a portion of the seal being between the outer circumferential face of the reactor component and the inner wall of the reactor tube such that the outer circumferential face and inner wall surface are not in contact with one another. 
     
     
       3. The reactor of  claim 1 , a portion of the seal being in contact with the outer circumferential face of the reactor component and the remaining portion of the seal extending outward from the outer circumferential face of the reactor component towards the inner wall surface of the reactor tube. 
     
     
       4. The reactor of  claim 3 , the portion of the seal extending outward from the outer circumferential face of the reactor component being at an angle of 30 to 70 degrees with the outer circumferential face. 
     
     
       5. The reactor of  claim 3 , the portion of the seal extending outward from the outer circumferential face of the reactor component being at an angle of 100 to 150 degrees with the outer circumferential face. 
     
     
       6. A reactor comprising: a. a reactor tube having an inner wall surface; b. a reactor component, the reactor component having an outer circumferential face, a top surface and a bottom surface, the reactor component being positioned in the reactor tube such that the outer circumferential face of the reactor component faces the inner wall of the reactor tube and a gap exists between the outer circumferential face of the reactor component and the inner wall of the reactor tube; c. a flexible, corrugated seal in direct contact with the inner wall surface of the reactor tube and the outer circumferential face, the top surface or the bottom surface of the reactor component, a portion of the flexible seal being positioned to substantially block fluid flow through the reactor between the outer circumferential face of the reactor component and the inner wall of the reactor tube. 
     
     
       7. The reactor of  claim 6 , the seal being made of metal foil and expandable in a radial direction. 
     
     
       8. The reactor of  claim 6 , a portion of the seal being in contact with the top surface or bottom surface of the reactor component and with the top surface or bottom surface of a second reactor component, the seal separating the reactor component and the second reactor component such that the reactor components are not in contact with one another. 
     
     
       9. The reactor of  claim 6 , a portion of the seal being in a ring shape and in contact with the outer circumferential face of the reactor component. 
     
     
       10. The reactor of  claim 9 , a separate portion of the seal extending outward at an angle towards the inner wall surface of the reactor tube.